Bulk bag with full perforation

ABSTRACT

A novel bag for holding, transporting, and pouring a bulk product is provided. The bag comprises a perforated section extending the majority of the way (and preferably the entire way) horizontally across the bag. The bag can be opened by tearing along the perforations and separating the resulting two sections of the bag. The bag is typically formed of plastic, and can be used for salt, animal food, and other pourable products.

RELATED APPLICATIONS

The present application is a continuation of U.S. patent application Ser. No. 13/413,319, entitled BULK BAG WITH FULL PERFORATION, filed Mar. 6, 2012, which is incorporated by reference herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is broadly concerned with the field of bags for holding pourable products such as salt, and more particularly bags having a perforated section that extends substantially, and preferably entirely, horizontally across the bag, for removal and pouring of the product from the bag.

2. Description of the Prior Art

Bag are commonly used to hold and transport pourable products (i.e., products comprising numerous small pieces). Such products include salt cubes or pellets, animal food, flour, and sugar, to name a few. These pourable products are typically sold in large quantities (e.g., 30-50 lbs.) and in bulk sizes that are difficult for the average person to handle. Even more difficult than carrying these bags is pouring the product from the bulky bag. That is, the consumer must open the bag, attempt to pick up the very heavy bag, and carefully pour the product in a controlled manner. This often results in spilling of the product, which goes from not coming out at all to rapidly falling from the bag and outside of the target area. There is a need for a bag that can be more easily opened at the point of use, as well as more easily poured with minimal or no spillage.

SUMMARY OF THE INVENTION

In one embodiment, the invention provides a bag for holding a pourable product. The bag comprises front and back panels comprising first and second end portions presenting respective outermost edges and first and second side portions presenting respective outermost edges. The front and back panels and the end and side portions cooperate to form a chamber for holding the pourable product. There is a width “W,” defined as the shortest distance between the respective outermost edges of the first and second side portions. The perforations extend from at least one of the respective outermost edges of the first and second side portions at a distance of at least about 50% of “W,” towards the other of the respective outermost edges of the first and second side portions.

In another embodiment, a method of using the above inventive bag is provided. The method comprises tearing the bag at the perforations to create an opening, and causing the pourable product to exit the bag from the opening, preferably by tilting the bag.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front elevation view of a bag according to the invention;

FIG. 2 is a rear elevation view of a bag according to the invention; and

FIG. 3 is a front elevation view illustrating the dimensions of a bag according to the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to FIGS. 1-3, a bag 10 is illustrated. Bag 10 includes a front panel 12 and a back panel 14. As shown, front and back panels 12, 14 are flat to demonstrate their respective shapes before being filled with product. Front panel 12 and back panel 14 share a first end portion 16 and a second end portion 18.

Front panel 12 and back panel 14 further share a first side portion 20 and a second side portion 22. First and second end portions 16, 18 and first and second side portions 20, 22 present respective outermost edges 24 a-d, which define an outer boundary or periphery 26 of the bag 10. Outermost edges 24 a and 24 b oppose, and are substantially parallel to, one another, while outermost edges 24 c and 24 d oppose, and are substantially parallel to, one another. Furthermore, outermost edges 24 c and 24 d are substantially perpendicular to outermost edges 24 a and 24 b.

Each of the first and second end portions 16, 18 intersects with first and second side portions 20, 22 at corners 28 a-d. Front and back panels 12, 14, first and second end portions 16, 18, and first and second side portions 20, 22 cooperate to form a chamber for holding a pourable product.

First end portion 16 comprises a first horizontal seam 30 spaced apart from outermost edge 24 a, thus forming a flap 32 in first end portion 16. First horizontal seam 30 has a thickness of from about 1/16 inch to about ¼ inch (and more preferably about ⅛ inch) and is substantially parallel to outermost edge 24 a. Flap 32 comprises a handle 34 formed therein. Handle 34 comprises a patch 36 that is heat-sealed to the flap 32. Patch 36 could be heat-sealed on either side of the flap 32 (i.e., on front panel 12 or on back panel 14), or on both sides if extra strength is required. Patch 36 can be any material typically used for bags carrying bulk products, including plastics such as linear low density polyethylenes (LLPDE). A C-shaped grip 38 is formed through patch 36 and flap 32 to form an opening, through which a user may place his or her fingers during carrying, pouring, etc.

Outmost edge 24 a of first end portion 16 is bisected by centerline 40 (see FIG. 3). In a preferred embodiment, handle 34 is positioned such that some portion of the grip 38 falls upon the centerline 40. Also, while it will be appreciated that the handle 34 is integrally formed with the bag 10 (and particularly with flap 32) as described above, one may also substitute an integrally formed handle with a separately formed handle that is then physically attached to the bag 10. The bag 10 further comprises perforations 42 in front and back panels 12, 14. Perforations 42 provide an area where the front and back panels 12, 14 can be separated, creating an opening for pouring of product from the bag 10. Ideally, perforations 42 form in a pattern that is linear in nature, and substantially parallel to outermost edges 24 a, 24 b and substantially perpendicular to outermost edges 24 c, 24 d. The figures depict perforations 42 extending from outermost edge 24 c to outermost edge 24 d, however, in some embodiments, the perforations 42 do not extend entirely across the width “W” of the front and back panels 12, 14. However, it is preferred that the perforations 42 extend at least about 50% of “W,” preferably at least about 75% of “W,” and more preferably about 100% of “W.” Furthermore, although the figures show the perforations 42 at a distance “D³” from outermost edge 24 b, it will be appreciated that the perforations 42 can be positioned anywhere along the length “L¹” of the front and back panels 12, 14, provided perforations 42 are at least about 0.5 inches, and preferably at least about 1 inch, from first horizontal seam 30 and outermost edge 24 b.

The bag 10 preferably has a side panel 44. Side panel 44 is essentially a lay-flat fold whose width is defined by a turn axis 46. Side panel 44 allows for expansion of the bag upon filling with the pourable product.

Referring to FIG. 3, several dimensions of the inventive bag 10 have been defined. The ranges for those dimensions are shown in Table 1.

TABLE 1 Preferred Bag Dimensions Most Dimension Broad Range Preferred Range Preferred Range from FIG. 3 (inches) (inches) (inches) L about 20 to about about 24 to about about 26 to about 35 30 28 W about 10 to about about 14 to about about 15 to about 24 20 18 D¹ about 2 to about about 2.2 to about about 2.4 to about 3.5 3 2.8 D² about 2 to about about 2.5 to about about 2.9 to about 4 4.5 3.2 D³* about 0.5 to about about 2 to about about 4 to about 10 8 7 L¹ about 17 to about about 20 to about about 22 to about 30 28 26 L¹/D³* about 2 to about about 2 to about about 3 to about 15 10 7 *Distance from either outermost edge 24b or first horizontal seam 30. **Unitless

The inventive bag 10 can be manufactured by various methods, but the preferred method is described herein. First, a tube or sleeve of plastic is cut to the desired length (represented by “L” in FIG. 3). The plastic of which the inventive bag is formed can be any material typically used to form bags carrying bulk products. The plastic should be flexible and stretchable so that the bag collapses as the bulk product is poured from the bag. Preferably, the plastic of which the bag is formed stretches from about 1 to about 2 times at yield, and more preferably about 1.5 times at yield. Furthermore, it is preferred that the bag be formed of a plastic that stretches at least about 4 times, preferably at least about 5 times, and more preferably from about 5 to about 7 times at its break point. Thus, the preferred plastic has an ASTM D882 percent elongation of from about 200% to about 800%, preferably from about 400% to about 700%, and more preferably from about 500% to about 650%. The thickness of the preferred plastic is from about 2 mil to about 14 mil, preferably from about 4 mil to about 10 mil, and more preferably from about 6 mil to about 8 mil. The most preferred material is LLDPE.

A heat seal is then applied at first end portion 16 in order to form horizontal seam 30. A film (typically having a 10-mil thickness) is heat-sealed to flap 32 to form patch 36. C-shaped grip 38 is then cut (e.g., die-cut) through the patch 36 and flap 32, thus forming handle 34, which serves as the primary carrying handle. The perforations 42 can be added at this time according to conventional methods.

The manufactured bag can then be stored until needed, or immediately filled and sealed. Either way, after the bag 10 is filled to the desired level, a final heat seal is applied at second end portion 18 to create second horizontal seam 44, making the filled bag 10 ready for distribution. It will be appreciated that the inventive bag 10 can be used to transport and store numerous types of pourable products, including cubes, pellets, tablets, powders, compacted pieces, and/or granules of those selected from the group consisting of: salt (e.g., water softening, pool treatment, deicing, etc.); animal food (e.g., bird seed, grain, dog or cat food); bulk flour or sugar; cement; seed (e.g., grass seed) and other lawn and garden products; fertilizers; ice; sand; rice; spices; soil (including soil mixtures); pesticides (e.g., fire ant treatments); industrial chemicals; mortar; plaster; marble dust; stones (including pebbles and gravel); and constructions products. Such products will typically cause the bags to weigh from about 20 lbs. to about 100 lbs., and more typically from about 40 lbs. to about 60 lbs.

In use and before pouring, a user would tear the front and back panels 12, 14 at perforations 42 in order to separate (or at least partially separate) strip 48 from the remainder 50 of bag 10. It will be appreciated that this allows for easy pouring of the product from the bag 10. This controlled pouring allows for fairly exact dispensing of the product, while preventing spillage and waste of the product. This type of opening is particularly advantageous in situations where the bag is being poured into a large opening. The user can just lay the bag on top of the large opening and use both hands to tear perforations 42 and separate strip 48 from remainder 50, thus avoiding the need to hold and tilt a heavy bag during product removal. 

We claim:
 1. A bag for holding a pourable product, said bag comprising front and back panels each comprising: first and second end portions presenting respective outermost edges; first and second side portions presenting respective outermost edges, said front and back panels and said end and side portions cooperating to form a chamber for holding the pourable product, there being a width “W,” defined as the shortest distance between the respective outermost edges of said first and second side portions; and perforations extending from at least one of said respective outermost edges of said first and second side portions a distance of at least about 50% of “W” towards the other of said respective outermost edges of said first and second side portions.
 2. The bag of claim 1, said perforations extending a distance of at least about 75% of “W.”
 3. The bag of claim 1, said perforations extending a distance of about 100% of “W.”
 4. The bag of claim 1, said perforations forming a linear pattern that is substantially parallel to at least one of said respective outermost edges of said first and second end portions.
 5. The bag of claim 1, said bag further comprising a handle adjacent at least one of said first and second end portions.
 6. The bag of claim 5, wherein said handle is at said first end portion.
 7. The bag of claim 5, wherein said handle is integrally formed with said bag.
 8. The bag of claim 1, wherein said chamber includes therein a quantity of a pourable product, said product being selected from the group consisting of salt, animal food, flour, sugar, cement, seed, fertilizer, ice, sand, rice, spices, soil, pesticides, industrial chemicals, mortar, plaster, marble dust, and stones.
 9. A method of dispensing a pourable product from a bag, the method comprising: providing a bag comprising front and back panels each comprising: first and second end portions presenting respective outermost edges; first and second side portions presenting respective outermost edges, said front and back panels and said end and side portions cooperating to form a chamber for holding the pourable product, there being a width “W,” defined as the shortest distance between the respective outermost edges of said first and second side portions; perforations extending from at least one of said respective outermost edges of said first and second side portions at a distance of at least about 50% of “W” towards the other of said respective outermost edges of said first and second side portions; and a quantity of the pourable product in said chamber; tearing said bag at said perforations to form an opening; and causing said pourable product to exit the bag through the opening.
 10. The method of claim 9, said perforations extending a distance of at least about 75% of “W.”
 11. The method of claim 9, said perforations extending a distance of about 100% of “W.”
 12. The method of claim 9, said perforations forming a linear pattern that is substantially parallel to at least one of said respective outermost edges of said first and second end portions.
 13. The method of claim 9, said bag further comprising a handle adjacent at least one of said first and second end portions.
 14. The method of claim 13, wherein said handle is at said first end portion.
 15. The method of claim 13, wherein said handle is integrally formed with said bag.
 16. The method of claim 9, wherein said pourable product is selected from the group consisting of salt, animal food, flour, sugar, cement, seed, fertilizer, ice, sand, rice, spices, soil, pesticides, industrial chemicals, mortar, plaster, marble dust, and stones.
 17. The method of claim 13, further comprising gripping said handle while causing said product to exit said bag.
 18. The method of claim 9, wherein said causing comprises tilting said bag. 